Packaging



March 1, 1966 J. E. DEREMER ETAL 3,237,760

PACKAGING Filed July 20, 1964 3 Sheets-Sheet 1 F151. FUSE.

INVENTOR.

ENSYS March 1, 1966 J. E. DEREMER ETAL 3,

PACKAGING Filed July 20 1964 3 Sheets-Sheet 2 INVENTOR. James E.08/?6776F Tobias J Har i/75 BY John w. Parenf March 1956 J. E. DEREMERETAL 3337 760 PACKAGING 3 Sheets-Sheet 3 Filed July 20, 1964 INVENTORfJames ,5. 0f Remer" 7612/05 Jf/ernngshaw BY uahn W- Parenf AT'IORNEYsUnited States Patent 3,237,760 PACKAGING James E. De Remer, Detroit,Mich, and Tobias J. Herringshaw, Toledo, and John W. Parent, Cleveland,Ohio, assignors to Continental Aviation and Engineering Corporation,Toledo, Ohio, a corporation of Virginia Filed July 20, 1964, Ser. No.383,717 8 Claims. (Cl. 20656) This invention relates to packaging andparticularly to a lightweight, reusable container utilizing a rigid foamplastic which completely encompasses the article being packaged.

In general there are two types of packages in widespread use today forprotecting assembled products during shipping. Heavy objects such asaircraft engines are usually packed by being carfully supported insidemetal containers which are ultimately shipped back to the manufacturerfor reuse. Smaller delicate objects are packed in disposable corrugatedcartons with impact protection being provided by some type of loosepacking such as strips of paper or by fitted pieces of corrugatedcardboard. Each of these methods of packaging has importantdisadvantages. For instance, metal containers have an initial cost whichis high, and small turbine engine containers with which we haveparticular experience cost well over three hundred dollars. In addition,costs for shipping are high due to the weight of these containers andthe engine supports, and if they are to be reused, it often costs asmuch as one-fifth the original cost to repair and repaint the containereach time it is to be reused. Further, metal will deteriorate and thuspackages made of it cannot be left exposed for any great length of time.

Corrugated packages are much less expensive than metal containers butthey do not have the necessary strength for carrying large and massiveobjects. In addition, such packages do not have the desired impactresistance for more delicate parts.

It is an object of the present invention to provide a relativelyinexpensive package for objects of any size or shape by providing acontainer which has a low initial cost and which is reusable withnegligible rehabilitation cost.

Another object of our invention is to provide a package which is ahermetically sealed enclosure, corrosion resistant, fire resistant,impact resistant, vibration dampening, and which will float indefinitelywithout damage to the packaged article by providing a package whichutilizes a rigid plastic foam material, such as polyurethane.

Still another object of the present invention is to minimize shippingcosts and handling problems by providing a package which is verylightweight, of small cost and capable of extensive stacking.

Yet another object of the present invention is to reduce the time andlabor required in packing and unpacking articles by providing a packagewhich may easily and quickly be packed and unpacked.

Still further objects and advantages will be readily apparent to oneskilled in the art upon reference to the following drawings in whichlike characters refer to like parts throughout the several views and inwhich FIG. 1 is a top elevational view of a base section of a preferredembodiment of the present invention showing structure designed to retainthe shape of the container during packaging.

FIG. 2 is a crosssectional view taken substantially on line 22 of FIG. 1but with the retaining structure removed.

FIG. 3 is a cross-sectional view similar to FIG. 2 but showing apreferred modification of the base section shown there.

, 3,237,766 Patented Mar. 1, 1966 FIG. 4 is an exploded perspective viewof an embodiment of the present invention illustrating a step in thepackaging of an article.

FIG. 5 is a perspective view of a preferred modification of theembodiment shown in FIG. 4.

FIG. 6 is a perspective view of the preferred embodiment illustratinganother step in the packaging of an article.

FIG. 7 is a perspective view of the preferred embodiment in completedform.

FIG. 8 is a cross-sectional view taken substantially on line 8 8 of FIG.7.

FIG. 9 is an exploded perspective view of the preferred embodimentillustrating a step in unpacking an article.

FIG. 10 is an exploded perspective View of another preferred embodimentof the present invention.

FIG. 11 is a lateral cross-sectional view of still another preferredembodiment of the present invention.

FIG. 12 is a cross-sectional view of a modification of the embodimentshown in FIG. 10, and

FIG. 13 is a perspective view of the package illustrated in FIG. 11.

Referring now to the drawings for a more detailed description of ourinvention, FIG. 1 shows a base section 10 preferably of corrugatedcardboard or similar construction such as weatherproof hardboard andhaving a floor portion 11 and upright walls 12 which define a baseenclosure 13. The floor portion 11 is provided with a plurality ofsquare perforations 14 equally spaced to form three lateral rows. Eachof the perforations 14- provides communication with the enclosure 13 andthe inside of a cardboard cube 15 having turned edges 16 stapled orotherwise fixed to the floor portion 11. The cubes 15 are sufficientlyhigh to provide a standard configuration for fork lifting and stacking.Where fork lift provisions are not required, ordinary containers withoutintegral pallets can be used to reduce the foam usage to a more uniformdistribution about the item packaged. Corner posts 17 of cardboard orsimilar construction are provided at the junctures of the upright walls12. The corner posts 17 preferably extend somewhat higher than the walls12.

Packaging begins by introducing a plastic foam material such aspolyurethane into each of the cubes 15 through the perforations 14. Thefoam material is preferably introduced by spraying and any of the manyfoaming systems now available may be employed for this purpose. Rigidpolyurethane foam is preferred since it hardens into a rigid yet foamingsubstance. The cubes 15 having been filled with foam, take on thenecessary strength needed for trucking and stacking. It even morestrength is required for these purposes a modified base section may beused as shown in FIG. 3. In this modification, the floor portion 111 isprovided with three rows of square perforations 114 each row of whichopens into a hollow rib structure 116, so that when the cubes 115 arefilled with rigid polyurethane foam a reinforced base section 110 isproduced.

After this has been completed, the rest of the base section 110 issubstantially filled with the foam as shown in FIG. 2. The foam is thenallowed to set until the foam has become resilient but before it hasreached a stage of rigidity. The exact amount of time for this stepdepends upon many variables including the mixture employed.

As best seen in FIG. 8, the article 18 which is to be packaged, in thiscase a motor, is preferably wrapped in two pieces of heavy paper orsimilar material. The inside wrapping is designated as 19 and theoutside 20. The outside wrapping 20 must in this embodiment of theinvention have the chracteristics of adhering to the foam and yieldingto the cutting action of the wire. The inside wrapping serves to protectthe article from foam dust and damage during opening, allow bettercontouring of the item packaged and provide a base for wire location andvarious materials are suitable for the purpose. Between these layers ofwrapping and completely encircling the article 18 is a thin wire 21preferably having grasping means 22 on one or both ends locatedexteriorly of the wrappings 19 and 20. This can best be seen in FIG. 4.

The article 18 including the wrappings 19 and 20 and the wire 21 isplaced upon the resilient foam retained in the base section 10. Sincethe foam has not yet become rigid, it will conform to the configurationof the lower part of the wrapped article 18 and will adhere to the outerwrapper 20.

A top box section 23 is provided with walls 24 each of which has a flapportion 25. The top section 23 is large enough to slide down over thecorner posts 17 and the walls 12 and completely cover these. Theinterior of the bottom section and the top section 23 wise secured toone of the flaps 25 as shown in FIG. 6.

The top section 23 is thereupon filled with foam. The

flaps 25 are closed and the package is preferably completed by providingretaining bands 26 as shown in FIG. 7.

Where ordinary containers are used a similar procedure of filling andclosing is employed.

Where the base section 10 and the top section 23 are constructed ofrather thin material or the package is large, a retaining structure 27,as shown in FIG. 1, may be used to prevent the plastic from pushing outthe sides of the container while it is hardening. Such a retainingstructure 27 preferably comprises a walled structure sufficiently largeto enclose the sides of the container. Each wall 28, which may be of apaneled or slotted construction, is provided with a hinged connection 29between it and its adjacent wall except that one of such junctures isprovided with latching means 30. This retaining structure is removedafter the foam has hardened and conformed to the inside contours of thebox.

The resultant package is suitable for labeling and stenciling. Datacarriers can be formed in place at the same time the item is foamed withopenings placed so as to be available at the surface of the foam.Weathering characteristics of the final package can be improved by theuse of triwall or similar materials or the foam block may be suitablycoated with one of the many available colored coatings.

When the package has reached its destination, it may be unpacked byfirst removing the bands 26 and then opening the flaps 25 exposing theend or ends of the wire 21 which may then be removed by loosening thetape or other fastening means. Since the interior of the top section 23has been treated with wax or a similar substance, it will be easilylifted or unfolded from the base section 10, exposing a unitary block ofrigid plastic encompassing the article 18. This block may be separatedinto two sections by simply pulling the wire 21 outwardly around thearticle 18 or where large thicknesses are involved by applying a voltagethrough the wire which will then be resistance heated (below red heatapproximately 300 F.) and will cut readily through the foam withoutburning.

Another configuration of value is the attachment of the foam pull wireto a second stripper wire built into the cardboard container so thatstripping of the container also cuts through the foam block. In thisconfiguration the foam is allowed to adhere to the container walls andthe container and foam block part in halves as a unit.

The outside wrapping 20, since it sticks to the foam, will permit easyremoval of the two sections of foam from the article 18 still protectedby the inside wrapper 19 as shown in FIG. 9. The impressions left in thetwo foam sections become paper lined molds into which more articles maybe placed for further shipping, being closed either by merely taping thefoam cube sections together or reconstituting a hermetic seal by use ofvarious adhesives.

It should be noted that while polyurethane is a strong material incompression, it can be cut quite easily. Thus the pull on wire 21 willnot have to be too great. The corner posts 17 act as fill, lessening theamount of foam which must be severed by the wire 21. If more sectionsare preferred, particularly on very irregularly shaped articles, severalpieces of wire 21 may be wrapped about the article 18 as shown in FIG.5.

FIG. 10 illustrates another preferred embodiment of the presentinvention utilizing unitary box 31 or corrugated cardboard or similarconstruction. A polyurethane bag 32 of a size approximately half thevolume of the box 31 is placed in the bottom of the box 31. The bag 32is filled with foam and the article 18 is placed upon this bag of foam32 before the plastic substance becomes hard. A second polyurethane bag33 of substantially the same size or smaller, depending on degree ofsupport or padding desired is placed on top of the article 18 and it toois filled with foam before the box 31 is closed. Upon opening after thefoam has hardened, the article 18 may be exposed by simply removing thebag 33.

In FIG. 12, an article 18 is illustrated as merely being supported,rather than being completely encased, by two foam-filled polyurethanebags 33A formed in the same way as the bags of FIG. 10.

In FIG. 5, the wires are shown to be wrapped around the outside wrapping35 of the article, which wrapping consists of a polyethylene bag. Whenthe wires are pulled to cut the foam, the pieces of foam will separatefrom the polyethylene. The impressions remaining in the foam-filled bagsprovide a mold into which the article will fit for reusing thecontainer.

FIGS. 11 and 13 illustrate yet another preferred embodiment of thepresent invention. A pair of sheets of perforated material 34 such aswire, synthetic screen or even a perforated polyethylene sheet or othermaterial to which the foam will not adhere, is placed in a plane aroundthe article 18 after it has been placed upon the resilient base. Thesheet 34 has edges 35 extending outside of the foam package. When thearticle has been covered by foam, the edges 35 remain outside the foamand provide means whereby the foam block may be separated into two ormore sections by simply pulling on these edges 35 as indicated-by thearrows of FIG. 13 to slice the foam along the plane of the sheet 34.Variations in number of perforations and adhesion of foam to the sheetmaterial can be employed to control separation forces and vapor barriercharacteristics.

It should be noted that the use of a box structure having a separatedbase section 10 and top section 23 is preferred where large articles areto be packaged since the smaller base enables the bottom to be reachedwith the necessary equipment for foaming with less difficulty than wouldbe encountered if a unitary box structure like that shown in FIG. 10were employed.

It is apparent from the foregoing description that our inventionprovides a package with important advantages not found in containerspresently being utilized. The following examples will help illustratethese advantages.

A metal container for packaging a 300 pound aircraft turbine enginecosts approximately $340.00. In addition, to this initial cost it costsapproximately $70.00 to prepare the package each time it is to bere-used. Because empty it weighs approximately 700 pounds, freightcharges to return it for re-use are very high. The foam package of thepresent invention for this same 300 pound engine would cost only $50.00.It can be prepared for re-use indefinitely by simply supplying a newcorrugated U outer pack as it deteriorates at a cost of approximately$4.00. Its empty weight is somewhat around 75 to 80 pounds, dependingupon the density of the material desired and for this reason, greatsavings can result in shipping costs both ways.

Further, the foam package of the present invention provides ahermetically sealed container, having extremely high impact resistanceand vibration dampening characteristics. Also, due to the properties ofthe polyurethane foam, the package will float high density items Withoutdamage to the packaged article due to the high buoyancy factor. It willnot deteriorate if left outside for long periods of time. The insulationand vapor barrier characteristics are extremely high. Finally, it isfire resistant as defined by Government specifications, and selfextinguishing since gases generated While burning tend to extinguish thefire.

Corrugated packages have heretofore been used for smaller articles. Theygenerally are not reusable since unpacking normally destroys thepackage. The initial cost of a foam package is approximatelythree-fifths that of a similar corrugated package. The foam package canbe refitted for reuse for about one-eighth the initial cost. It weighshalf that of a similar corrugated package and thus produces a savingsover such packages in freight costs. Further, corrugated packages havelow impact resistance, no weather resistance, will float only for ashort period of time and are readily burned.

Although only several preferred embodiments of the invention have beendescribed, it will be apparent to one skilled in the art to which theinvention pertains that various changes and modifications may be madetherein without departing from the spirit of the invention or the scopeof the appended claims.

We claim:

1. A method of preparing a-package for an article comprising: preparinga container having a bottom provided with downwardly extending hollowleg members openly communicating with the interior of the container, andintroducing an amount of rigid foaming plastic into said leg memberssumcient to fill same whereupon said leg members become supportingpallets for said container.

2. The method of preparing a package as defined in claim 1 and includingthe subsequent step of introducing into said container after apredetermined interval in which the plastic in the legs has begunsolidifying a further quantity of said rigid foaming plastic sufiicientto form a base in the bottom of the container in contact with theplastic in said legs.

3. A packaging container comprising a carton having a bottom, and hollowlegs disposed on the exterior side of said bottom and openlycommunicating with the interior of said carton.

4. Tie container as defined in claim 3 and in which said carton bottomis provided with openings communicating with the interior of said legs.

5. The container as defined in claim 3 and having hollow stiffenermembers exteriorly of said carton bottom and connecting said legs, theinside of said stiffener members openly communicating with the interiorof said carton.

6. The container as defined in claim 3 and having hollow stiffenermembers exteriorly of said carton bottom and connect ng said legs, theinside of said stiffener members openly communicating with the interiorof said legs.

7. A packaging means comprising (a) a carton,

(b) hollow legs affixed to said carton and having the interior thereofcommunicating with the interior of said carton,

(c) an article to be packaged carried in said carton,

(d) a rigid plastic foam in said carton and in the interior of saidhollow legs, said rigid plastic foam encasing said article.

8. The packaging means as defined in claim 7 and including a wiredisposed intermediate said foam and said article and completelyencompassing said article and the ends of said wire extending outwardlythrough said foam to a point adjacent the interior surface of saidcarton.

References Cited by the Examiner UNITED STATES PATENTS 2,465,148 3/1949Coonen 108-51 2,956,670 10/1960 Marshall 20646 3,090,331 5/1963 McCann108-51 3,124,246 3/1964 De Remer et a1 20656 THERON E. CONDON, PrimaryExaminer.

7. A PACKAGING MEANS COMPRISING (A) A CARTON, (B) HOLLOW LEGS AFFIXED TOSAID CARTON AND HAVING THE INTERIOR THEREOF COMMUNICATING WITH THEINTERIOR OF SAID CARTON, (C) AN ARTICLE TO BE PACKAGED CARRIED IN SAIDCARTON, (D) A RIGID PLASTIC FOAM IN SAID CARTON AND IN THE INTERIOR OFSAID HOLLOW LEGS, SAID RIGID PLASTIC FOAM ENCASING SAID ARTICLE.